Coated food product

ABSTRACT

There is provided a method for preparing a coated food product comprising: (a) coating the food product in a first step with a layer of a first liquid mixture comprising a seasoning and an oil or fat; (b) coating the coated food product obtained in step (a) in a second step with a layer of a second liquid mixture comprising from a binder, cobinder; and water; wherein the weight ratio in the second liquid mixture of binder to cobinder is of from 5:1 to more than 1:1; and (c) drying the coated food product obtained in step (b). Coated product obtainable thereof are also herein provided. This method is particularly beneficial for products with large and/or heavy seasonings.

DESCRIPTION OF THE INVENTION

The present invention relates to a coated food product, in particular acoated food product having at least two layers, wherein the coated foodproduct is selected from the group consisting of oven baked foodproducts, deep fried crisps, extruded products, dry roasted nuts andgeneral dry food products having a water content of less than 5 percentby weight, calculated on the total weight of said general dry foodproduct, said general dry food product being made of materials selectedfrom the group consisting of cereals, preferably wheat and corn, potatoand rice. The present invention in particular relates to coated-pretzelswhich are coated with at least two layers.

BACKGROUND OF THE INVENTION

As is well known in the art, seasoning or flavoring of food products ishampered by several serious drawbacks.

A first disadvantage is that the addition of seasonings or flavors to afood product in a food manufacturing process leads to the formation ofdust of the seasonings or flavors which is a healthy risk factor for theemployees. Additionally, the formation of dust can lead to crosscontamination with other food products made in the same factory.

Another major disadvantage is that added seasonings or flavors do poorlyadhere to the food product with the result that the seasonings orflavors fall of the food during transport, packaging, storage andconsumption of the food product. This leads to poorly flavored productsat the time of consumption and to undesired loss of flavor ingredients.This problem becomes even more acute when attempts are made with largeand/or heavy pieces of seasonings. By “large”, it is meant that thepieces of seasonings have an average size ranging of at least 0.5 mm, inparticular between 1 and 2 mm.

The problems described above occur in particular in the production offlavored pretzels. Pretzels contain about one percent by weight ofmoisture and are immersed in caustic soda (sodium hydroxyde) prior tothe baking process to provide the desired color. However, this immersionstep also provides a smooth surface to the pretzel with the result thatflavors do not or hardly adhere to said surface. Although it has beenattempted to produce flavored pretzels by introducing the flavors intothe dough, due to the baking process, the flavors decompose whichrenders an unacceptable and undesirable taste to the pretzel.Alternatively, after the baking process a slurry of fat and flavors canbe applied to cooled pretzels. However, this has disadvantages as wellsince the consumer will end up with greasy hands and fingers whileeating the pretzels. Moreover, in the common production process pretzelsare baked in an oven at a temperature of about 90° C. and any oil or fatwhen applied to hot pretzels is adsorbed by the pretzels in about thirtyseconds with the result that the flavors do no longer adhere to thesurface of the pretzel. Hence, the application of slurries of oil or fatand flavors to either hot or cooled pretzels does also not produceacceptable flavored pretzels.

Several solutions are provided in the art for the technical problemsdescribed above. For example, U.S. Pat. No. 4,161,545 discloses aprocess for a honey coated roasted nut wherein raw nuts are first coatedwith a mixture comprising about 50 to 80 percent by weight of honey andabout 20 to 50 percent by weight of water, said mixture preferablycontaining about 40 to 70 percent by weight of soluble solids.Subsequently, the honey coated nuts are coated with a dry mixturecontaining about 84 to 92 percent by weight of sugar and about 8 to 16percent by weight of starch and finally the nuts are roasted. If thesolids content of the honey containing mixture is on the low side of the40 to 70 percent by weight range of soluble solids, the honey containingmixture preferably also contains a binder such as maltodextrins,dextrins, natural or derived edible polymers, arabic gum, guar gum andcellulose derivatives. Consequently, according to the method disclosedin U.S. Pat. No. 4,161,454 the first layer is applied as a liquidcomposition and the second layer as a dry composition.

U.S. Pat. No. 4,769,248 discloses a process for the preparation of dryroasted nuts comprising applying a first (dry) layer of starch to rawnuts followed by the application of a gelatin solution. Subsequently, adry coating of seasonings is applied and finally the nuts are roasted.Consequently, according to the method disclosed in U.S. Pat. No.4,769,248 the first layer is applied as a dry composition and the secondlayer as a liquid composition.

U.S. Pat. No. 5,571,546 discloses a multiple coated food product whereinthe first coating layer comprises two layers comprising amylose,amylopectin and a minor quantity of disaccharide in different ratios anda second coating layer comprising amylose and amylopectin in a ratio ofnot less than 1:0.8. Alternatively, the first coating layer may comprisenon-pregelatinised waxy starch and optionally non-waxy starch and thesecond layer may comprise non-waxy starch. The coating layers arepreferably applied as dry mixtures or aqueous solutions or suspensionsof the layer components.

U.S. Pat. No. 5,599,569 discloses a method for adhering a seasoning to afood product, said method comprising the steps of: coating the foodproduct with a solution containing an amylase treated starch, adheringthereon at least one seasoning, flavorant, or colorant, and drying theresultant food product.

U.S. Pat. No. 5,798,132 discloses a method for preparing a coated foodproduct, wherein a coating composition comprising an oil-in-wateremulsion, ungelatinised starch, and a seasoning is applied to the foodproduct, where after the food product is subjected to a two stage dryingprocess. The food product disclosed in U.S. Pat. No. 5,798,132 has onlyone layer.

U.S. Pat. No. 6,294,208 discloses a method for the production of highlyseasoned chips, wherein a base chip is coated with an oleaginouscomposition comprising a seasoning followed by adhering a dry seasoningmaterial. The oleaginous composition comprises an oil from an animalsource, an oil from a vegetable source or a non-nutritive oil.Consequently, according to the method disclosed in U.S. Pat. No.6,294,208 the first layer is applied as a liquid composition and thesecond layer as a dry composition.

EP A 841.012 discloses a method for the preparation of a snack product,in particular a coated nut, wherein the nut is first coated with a pastelayer of flour. This first layer may be applied by bringing the nuts ina rotating drum and by adding flour in powder form and simultaneouslyspraying water. The second layer is an adhesive layer and is applied bybattering or gumming a mixture of water and adhesive. Subsequently, alayer of bread crumbs is applied and finally the nut is fried. Flavors,aromas and seasonings may be added during the application of theadherent layer or the bread crumb layer. Consequently, the flavors,aromas and seasonings are not present in the first layer.

WO 01/05256 discloses a method for coating a food product by dipping in,tumbling or spraying the food product with a coating compositioncomprising a suspension of particles in a carrier oil, wherein saidparticles have a particular particle size and a particular particle sizedistribution. The particles comprise essentially flavoring or seasoningcomponents and optionally carriers or diluents. Hence, the food productaccording to WO 01/05256 has only one layer.

U.S. Pat. No. 4,910,031 describes savoury snack food topped withsubstances by means of a non sweet sugars based binder. In particularexample II describes the coating with a binder comprising 65 wt. %sucrose of dried corn collets previously sprayed with oil, cheddarcheese and salt.

GB 1,257,720 describes animal foods comprising porous expanded chunkscovered with a coating of fat and flavours; the fat coated chunks havinga further coating comprising dextrin and optionally a flavouringadditive such as sucrose. Exemplified are dextrin coating compositionsmade of 23 parts dextrin and 2 parts sucrose.

U.S. Pat. No. 5,132,125 describes corn kernels coated with an edibleoleaginous substance or edible wax optionally comprising flavourings,and thereafter covered with an outer shell comprising an ediblepolymeric material and an anti-fragility and palatability enhancer suchas sugar, whereby the corn kernels treated therewith exhibit completepopping and are less prone to drying. In particular example I disclosesan outer shell composition made of a liquid mixture of 1.5 wt % aqueousalgin and 0.15 wt. % glycerine.

The methods according to the prior art are still insufficient withrespect to seasoning or flavor adherence. In particular, it is an objectof the invention to provide a method with good adherence of theseasoning and/or flavour and/or decorations so-called hereinafter“toppings”, especially when large and/or heavy pieces of such toppingsare considered. Of course, by “topping” is also encompassed that morethan one topping is included.

SUMMARY OF THE INVENTION

The present invention therefore relates to a method for preparing acoated food product comprising:

(a) coating the food product in a first step with a layer of a firstliquid mixture comprising a topping and an oil or fat;

(b) coating the coated food product obtained in step (a) in a secondstep with a layer of a second liquid mixture comprising from:

-   -   i) 5 to 40 wt. % of a binder selected from selected from the        group consisting of maltodextrins having a dextrin equivalent in        the range of 0.1 to 10, dextrin, edible polymers, arabic gum,        guar gum and cellulose derivatives;    -   ii) 5 to 40 wt. % of a co-binder selected from the group        consisting of monosaccharides, disaccharides and mixtures        thereof; and    -   iii) 20 to 90 wt. % water

c) drying the coated food product obtained in step (b); and

wherein in step b) the weight ratio in the second liquid mixture ofbinder to co-binder is of from 5:1 to more than 1:1.

Alternatively, the components of the first liquid mixture may be addedseparately but simultaneously or subsequently so that a layer of fat oroil is sprayed onto the food product onto which layer the topping isapplied prior to the application of the second liquid mixture.Accordingly, there is also provided herein a method for preparing acoated food product comprising:

(a) coating the food product in a first step with a layer of an oil orfat and the simultaneous or subsequent coating of said product with alayer of a topping;

(b) coating the coated food product obtained in step (a) in a secondstep with a layer of a second liquid mixture comprising from:

-   -   i) 5 to 40 wt. % of a binder selected from selected from the        group consisting of maltodextrins having a dextrin equivalent in        the range of 0.1 to 10, dextrin, edible polymers, arabic gum,        guar gum and cellulose derivatives;    -   ii) 5 to 40 wt. % of a co-binder selected from the group        consisting of monosaccharides, disaccharides and mixtures        thereof; and    -   iii) 20 to 90 wt. % water

(c) drying the coated food product obtained in step (b); and

wherein in step b) the weight ratio in the second liquid mixture ofbinder to co-binder is of from 5:1 to more than 1:1.

Advantages of the present invention are less dust formation in foodfactories, less fall off and hence a lower loss of flavors andseasonings during storage, transport, packaging and consumption of thefood product. Additionally, the method is suitable for topping foodproducts which so far could not or hardly not be topped, in particularpretzels.

Optionally, the coated food product obtained in step (a) may first bedried before it is subjected to step (b).

DETAILED DESCRIPTION OF THE INVENTION

According to the present invention, the food product is preferablyselected from the group consisting of oven baked food products, deepfried crisps, extruded products, dry roasted nuts, toasted products andgeneral dry food products having a water content of less than 5 percentby weight, calculated on the total weight of said general dry foodproduct, said general dry food product being made of materials selectedfrom the group consisting of cereals, preferably selected from wheat,corn, potato, rice and mixtures thereof, more preferably selected fromwheat and corn, potato and rice. The oven baked food product ispreferably selected from the group consisting of biscuits, cookies,pretzels, toasts, crackers, and snacks, and is in particular pretzels.The extruded products are preferably deep fried after extrusion.

The oil or fat is preferably selected from the group consisting ofedible and vegetable oils. Examples of such oils are olive oil, palmoil, coconut oil, corn oil, line seed oil, peanut oil, rape seed oil,sesame oil, soy been oil, sunflower oil and mixtures thereof.

Suitable toppings for the purpose of the present invention are selectedfrom flavours, seasonings, decorations, and mixtures thereof.Advantageously, larger and/or heavier pieces of toppings thanconventionally used can now be used with the present method. Hence,toppings, in particular seasonings of sizes greater than 0.5 mm,preferably between 0.5 and 2 mm, more preferably between 0.8 and 2 mm,most preferably between 1 and 2 mm as measured with a Sieve can now beconsidered for use in the present invention as toppings. Accordingly,for the purpose of the present invention, there is also provided acoated food product which contains toppings with a size greater than 0.5mm, preferably between 0.5 and 2 mm, more preferably between 0.8 and 2mm, most preferably between 1 and 2 mm. More in particular, the coatedfood product contains more than 50% of the topping particles with a sizegreater than or equal to 1 mm, more preferably more than 10% of thetopping particles with a size between 1 mm and 2 mm.

A preferred type of topping is a seasoning. The seasoning is preferablya sweet seasoning or a savory seasoning, the latter optionally having asour like lemon taste. The seasoning has preferably an average diameterof about 0.1 to 2.0 mm, more preferably 0.2 to 1.5 mm. The topping, inparticular seasoning, is well visible on the final coated food product.

According to the invention, the binder is preferably selected from thegroup consisting of maltodextrins, dextrins, edible polymers, arabicgum, guar gum and cellulose derivatives. The binder is in particular amaltodextrin, preferably a maltodextrin having a dextrin equivalent inthe range of 0.1 to 10 which implies that it preferably contains a lowamount of reducing sugars.

The edible polymers are preferably selected from the group consisting ofproteins, starches and polysaccharides.

According to the present invention, the co-binder is selected frommonosacchrides, disaccharides, and mixtures thereof, preferably is adisaccharide. Suitable monosaccharides are those of the hexose type, inparticular those selected from fructose, glucose and mixtures thereof. Asuitable and most preferred disaccharide is sucrose, in particularsucrose in powder form such as icing sugar.

According to the present invention, the first liquid mixture comprisinga topping and an oil or fat comprises preferably 5.0 to 60.0 percent byweight of seasoning, more preferably 15.0 to 50.0 percent by weight andin particular 25.0 to 45.0 percent by weight, and 40.0 to 95.0 percentby weight of the oil or fat, more preferably 50.0 to 85.0 percent byweight and in particular 55.0 to 75.0 percent by weight, based on thetotal weight of the mixture. Typically, the topping will represents from2 to 20%, preferably 4 to 15% and more preferably from 5 to 10% byweight of the coated food product and the fat will represent of from 2to 20%, preferably of from 3 to 15% by weight of the coated foodproduct. Preferably, the weight ratio of fat or oil to topping is offrom 3:1 to 1.5:1, more preferably from 2.5:1 to 2:1, most preferably isof 2:1. Where the component of the first liquid mixture are applied,typically by spraying, separately but simultaneously or subsequently, ithas advantageously been found that a coated product of a low fat contentcould be obtained whilst still presenting the beneficial properties oftopping sticking, size and content. By low fat content, it is meant thatcoated food products with a content of less than 10% by weight,preferably less than 5% by weight and more preferably between 2 and 4%by weight, in particular 3.5% by weight of the coated food product. Thesecond liquid mixture comprising a binder, a co-binder and watercomprises 5.0 to 40.0 percent by weight of binder, more preferably 10.0to 40.0 percent by weight and in particular 20.0 to 40.0 percent byweight, and 5.0 to 40.0 percent by weight of co-binder, more preferably10.0 to 40.0 percent by weight and in particular 20.0 to 40.0 percent byweight, and water to sum up to 100%, preferably in amount of from 20.0to 90.0 percent by weight of water, more preferably 20.0 to 80.0 percentby weight and in particular 20.0 to 60.0 percent by weight, based on thetotal weight of the mixture. Preferably, the liquid mixture comprisingthe binder, co-binder and water contains the binder and co-binder inweight ratio between 5:1 to more than 1:1, more preferably between 3:1to 1.1:1 and in particular between 2:1 and 1.5:1.

For optimum adherance and protection of the topping, it is preferredthat the second liquid mixture presents a viscosity in the range of 20to 70, preferably from 25 to 50, more preferably from 28 to 30 mPa, whenmeasured with a Brookfield Model DV-II viscosimeter with RVT 2 at 30 rpmand at a temperature of 80° C.

Optionally, a flavour enhancer may be used in the second liquid mixturewhich will provide flavour enhancement but also improved protection ofthe topping applied onto the food product. A typical flavour enhancerfor use herein is a yeast such as Yep, in particular Yep 77, andcommercially available from Quest international. Other optionalingredients can also be added to the second liquid mixture such assalts. Typical amount of each of such optional ingredient ranges from0.1 to 5%, preferably from 0.5% to 1.5% by weight of the second liquidmixture.

The weight ratio of the liquid comprising the topping and the oil or fatand the liquid mixture comprising the binder, co-binder and water ispreferably 10:1 to 1:2, more preferably 8:1 to 1:1 and in particular 6:1to 2:1.

In the last step according to the method of the present invention, thefood product is dried in step (c) to a moisture content of preferablynot more than about 7% by weight, more preferably not more than about 5%by weight and in particular not more than about 3% by weight.

The present invention also relates to a coated food product obtainableby the method described above. In particular, the topping adhered to thefinal coated food product is well visible and the food product has anattractive appearance for the consumer. Further, the topping can be of alarger size and/or heavier weight than conventionally used toppingwithout being detrimental to the adherence performance of the toppingonto the food product.

EXAMPLE 1

A slurry is prepared by adding 45 g of powder flavor with 80 g to aspray fat (Durkex LC 200; obtainable from Loders Croklaan). Thedispersion is stored at 50° C.

A coating composition is prepared by dissolving at 80° C. 60 g ofmaltodextrin MD 10 and 40 g of icing sugar with 0.08 g salt and 0.08 gYep 77 in 100 g of water. The composition is maintained at the sametemperature in a holding tank.

A food product (400 g; moisture content of 1.5%) is transported at atemperature of 90° C. via a belt to a tumbler. In the tumbler 125 g ofthe dispersion is sprayed on the food product during 30 s, while keepingthe temperature at 90° C. Subsequently, 30 g of the coating compositionis added to the same tumbler and is sprayed on the coated food productwithin 30 s. Finally, the coated food product is dried in the tumblerfor about 5 minutes.

EXAMPLE 2

The food product according to Example 1 was after drying further driedin a second tumbler until a moisture content of 1%.

EXAMPLE 3

A food product (400 g; moisture content of 1.5%) is transported at atemperature of 90° C. via a belt to a tumbler. In the tumbler thedispersion of fat Durkex LC 200; obtainable from Loders Croklaan) andflavour present in the dispersion at a weight ratio of 2:1 is sprayed onthe food product during 30 s, while keeping the temperature at 90° C.Subsequently, 30 g of the coating composition made according to theprocess given in Example 1 and containing 30 g maltodextrin MD 10 and 20g of icing sugar with 0.08 g salt and 0.08 g Yep 77 in 49.84 g of wateris added to the same tumbler and is sprayed on the coated food productwithin 30 s. Finally, the coated food product is dried in the tumblerfor about 5 minutes followed thereafter by a further drying step in asecond tumbler until a moisture content of 1%.

The resulting coated food product had the following composition in wt %:Food product 77 Fat 10.79 Flavour 5.39 Coating 6.74

EXAMPLE 4

A food product (400 g; moisture content of 1.5%) is transported at atemperature of 90° C. via a belt to a tumbler. In the tumbler the fat(Durkex LC 200; obtainable from Loders Croklaan) is sprayed on the foodproduct during 30 s, with the simultaneous spraying of the topping whilekeeping the temperature at 90° C. Subsequently, 30 g of the coatingcomposition made according to the process given in Example 1 andcontaining 30 g maltodextrin MD 10 and 20 g of icing sugar with 0.10 gsalt and 0.51 g Yep 77 in 49.39 g of water is added to the same tumblerand is sprayed on the coated food product within 30 s. Finally, thecoated food product is dried in the tumbler for about 5 minutes followedthereafter by a further drying step in a second tumbler until a moisturecontent of 1%.

The resulting coated food product had the following composition in wt %:Food product 72 Fat 3.63 Flavour 5.81 Coating 16.53 Particles* 1.45*Particles with a size greater than 0.5 mm, of which more than 50% havea size equal or greater than 1 mm

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 17. A method for preparing a coated food productcomprising: (a) coating the food product in a first step with a layer ofa first liquid mixture comprising toppings with a size greater than 0.5mm and an oil or fat; (b) coating the coated food product obtained instep (a) in a second step with a layer of a second liquid mixturecomprising: 5 to 40 wt. % of a binder selected from the group consistingof maltodextrins having a dextrin equivalent in the range of 0.1 to 10,dextrin, edible polymers, arabic gum, guar gum and cellulosederivatives; 5 to 40 wt. % of a co-binder selected from the groupconsisting of monosaccharides, disaccharides, and mixtures thereof; and20 to 90 wt. % water; and (c) drying the coated food product obtained instep (b); and wherein in step (b) the weight ratio in the second liquidmixture of binder to co-binder is of from 5:1 to more than 1:1.
 18. Themethod according to claim 17, wherein the coated food product obtainedin step (a) is dried.
 19. The method according to claim 17, wherein thefood product is selected from the group consisting of oven baked foodproducts, deep fried crisps, extruded products, dry roasted nuts andgeneral dry food products having a water content of less than 5 percentby weight, calculated on the total weight of said general dry foodproduct, said general dry food product being made of materials selectedfrom the group consisting of cereals, preferably wheat and corn, potatoand rice.
 20. The method of claim 19, wherein the oven baked foodproduct is selected from the group consisting of biscuits, cookies,pretzels, crackers, and snacks.
 21. The method of claim 20, wherein theoven baked food product is pretzels.
 22. The method according to claim19, wherein the extruded products are deep fried after extrusion. 24.The method according to claim 17, wherein the oil or fat is selectedfrom the group consisting of edible and vegetable oils.
 25. The methodaccording to claim 17, wherein the edible polymers are selected from thegroup consisting of proteins, starches and polysaccharides.
 26. Themethod according to claim 17, wherein the first liquid mixturecomprising a topping and an oil or fat comprises 5.0 to 60.0 percent byweight of topping and 40.0 to 95.0 percent by weight of the oil or fat,based on the total weight of the mixture.
 27. The method according toclaim 17, wherein the weight ratio of binder to co-binder in the secondliquid mixture is between 3:1 to 1.1:1.
 28. The method according toclaim 17, wherein in step (c) the food product is dried to a moisturecontent of not more than about 7%.
 29. The method according to claim 17,wherein the topping has an average size of 0.5 mm with more than 50% ofthe topping particles with a size greater than or equal to 1 mm.
 30. Themethod according to claim 17, wherein the second liquid mixture furthercomprises a flavor enhancer.
 31. The method according to claim 30,wherein the flavor enhancer is a yeast.
 32. A method for preparing acoated food product comprising: (a) coating the food product in a firststep with a layer of an oil or fat and the simultaneous or subsequentcoating of said product with a layer of toppings with a size greaterthan 0.5 mm; (b) coating the coated food product obtained in step (a) ina second step with a layer of a second liquid mixture comprising: 5 to40 wt. % of a binder selected from the group consisting of maltodextrinshaving a dextrin equivalent in the range of 0.1 to 10, dextrin, ediblepolymers, arabic gum, guar gum and cellulose derivatives; 5 to 40 wt. %of a co-binder selected from the group consisting of monosaccharides,disaccharides, and mixtures thereof; and 20 to 90 wt. % water; and (c)drying the coated food product obtained in step (b); and wherein in step(b) the weight ratio in the second liquid mixture of binder to co-binderis of from 5:1 to more than 1:1.
 33. The method according to claim 32,wherein the coated food product obtained in step (a) is dried.
 33. Themethod according to claim 32, wherein the food product is selected fromthe group consisting of oven baked food products, deep fried crisps,extruded products, dry roasted nuts and general dry food products havinga water content of less than 5 percent by weight, calculated on thetotal weight of said general dry food product, said general dry foodproduct being made of materials selected from the group consisting ofcereals, preferably wheat and corn, potato and rice.
 34. The method ofclaim 33, wherein the oven baked food product is selected from the groupconsisting of biscuits, cookies, pretzels, crackers, and snacks.
 35. Themethod of claim 34, wherein the oven baked food product are pretzels.36. The method according to claim 32, wherein the extruded products aredeep fried after extrusion.
 37. The method according to claim 32,wherein the oil or fat is selected from the group consisting of edibleand vegetable oils.
 38. The method according to claim 32, wherein theedible polymers are selected from the group consisting of proteins,starches and polysaccharides.
 39. The method according to claim 32,wherein the first liquid mixture comprising a topping and an oil or fatcomprises 5.0 to 60.0 percent by weight of topping and 40.0 to 95.0percent by weight of the oil or fat, based on the total weight of themixture.
 40. The method according to claim 32, wherein the weight ratioof binder to co-binder in the second liquid mixture is between 3:1 to1.1:1.
 41. The method according to claim 32, wherein in step (c) thefood product is dried to a moisture content of not more than about 7%.42. The method according to claim 32, wherein the topping has an averagesize of 0.5 mm with more than 50% of the topping particles with a sizegreater than or equal to 1 mm.
 43. The method according to claim 32wherein the second liquid mixture further comprises a flavor enhancer.44. The method according to claim 43 wherein the enhancer is a yeast.